Cummins operation and Maintenance B & C marine propulsion.

Operation and Maintenance Manual B and C Series Marine Propulsion Units Worldwide

Operation and Maintenance Manual B and C Series Marine Propulsion Units Worldwide 4BT 3.9M 6BTA 5.9M2 6CTA 8.3M1 6CTA 8.3M2 Copyright© 1994 Cummins Engine Company, Inc. All rights reserved Bulletin No. 3666022-02 Printed 05-94

Foreword This manual contains information for the correct operation and maintenance of your Cummins engine. It also includes important safety information, engine and systems specifications, troubleshooting guidelines, and listings of Cummins Authorized Repair Locations and component manufacturers. Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner. The information, specifications, and recommended maintenance guidelines in this manual are based on information in effect at the time of printing. Cummins Engine Company, Inc. reserves the right to make changes at any time without obligation. If you find differences between your engine and the information in this manual, contact your local Cummins Authorized Repair Location. The latest technology and the highest quality components were used to produce this engine. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts can be identified by the following trademarks: m u HOLSET MM W ^ B lu e Note: Warranty information is located in Section W. Make sure you are familiar with the warranty or warranties applicable to your engine.

Table of Contents Section Introduction ....................................................................................................................................................... i Engine Identification....................................................................................................................................... E Operating Instructions................................................................................................................. 1 Maintenance Guidelines................................................................................................................................. 2 Maintenance Procedures - Daily or Every 20 Hours .............................................................................. 3 Maintenance Procedures - 3 Months or 250 Hours .............................................................................. 4 Maintenance Procedures - 6 Months or 500 Hours .............................................................................. 5 Maintenance Procedures -1 2 Months or 1000 Hours ............................................................................ 6 Maintenance Procedures - 24 Months or 2000 Hours .......................................................................... 7 System Diagrams............................................................................................................................................ D Troubleshooting.............................................................................................................................................. T Adjustment, Repair and Replacement........................................................................................................ A Specifications and Torque Values................................................................................................................ V Service Assistance .......................................................................................................................................... S Component Manufacturers............................................................................................................................ C Warranty............................................................................................................................................................. W Service Literature............................................................................................................................................. L Index .................................................................................................................................................................... X

Important Reference Numbers Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever service or maintenance is required. Port Starboard Engine Model______________________________ _______________________ _______________________ Engine Serial Number _______________________ _______________________ _______________________ Engine Control Parts List (CPL) Number _______________________ _______________________ Engine Oil Type and Viscosity _______________________ _______________________ Engine Specification Number _______________________ _______________________ Fuel Pump Part Number _______________________ _______________________ Filter Part Numbers: • Air Cleaner Element_____________________ _______________________ _______________________ • Coolant (C-Series)_______________________ _______________________ _______________________ • Lubricating Oil__________________________ _______________________ _______________________ • Fuel___________________________________ _______________________ _______________________ • Fuel Water Separator____________________ _______________________ _______________________ Belt Part Number __________ ____________ _______________________ Marine Gear Manufacturer _______________________ _______________________ Marine Gear Model _______________________ _______________________ Marine Gear Serial No. _______________________ _______________________ Marine Gear Part Number _______________________ _______________________ Marine Gear Oil Type _______________________ _______________________ Raw Water Pump Manufacturer _______________________ _______________________ Raw Water Pump Model _______________________ _______________________ Raw Water Pump Part Number _______________________ _______________________

Models Included in this manual are: KW No. Model [BHP] CPL RPM * Rating (Duty Cycle) 1. 4B 48 [64] 0591 2200 Continuous 2. 4B 57 [76] 0591 2500 Medium Continuous 3. 4B 60 [80] 0721 2800 Recreation/Light Duty 4. 4BT 97 [130] 0741 2500 Medium Continuous 5. 4BT 112 [150] 0741 2800 Recreation/Light Duty 6. 6B 73 [98] 0714 2200 Continuous 7. 6B 86 [115] 0714 2500 Medium Continuous 8. 6B 90 [120] 0791 2800 Recreation/Light Duty 9. 6BT 113 [152] 1289 2500 Medium Continuous 10. 6BT 134 [180] 0742 2500 Medium Continuous 11. 6BT 157 [210] 0742 2600 Recreation/Light Duty 12. 6BTAM1 164 [220] 1570 2500 Medium Continuous 13. 6BTAM1 186 [250] 1570 2600 Recreation/Light Duty 14. 6BTAM2 164 [220] 1613 2500 Medium Continuous 15. 6BTAM2 186 [250] 1613 2600 Medium Continuous 16. 6BTAM2 224 [300] 1613 2800 Recreation/Light Duty 17. 6BTAM2 235 [315] 1928 2800 High Output 18. 6CTAM1 186 [250] 1221 2100 Continuous 19. 6CTAM1 224 [300] 1221 2500 Medium Continuous 20. 6CTAM2 298 [400] 1282 2600 Recreation/Light Duty 21. 6CTAM2 313 [420] 1929 2600 High Output *Note: Detailed definitions of the Rating Terminology is covered in Section E.

Section i - Introduction Section Contents Page About the Manual ..................................................................................................................................................................... i-2 Definition of Terms................................................................................................................................................................ i-11 General Cleaning Instructions............................................................................................................................................ i-10 General Repair Instructions................................................................................................................................................... i-9 General Safety Instructions ................................................................................................................................................... i-8 How to Use the Manual .......................................................................................................................................................... i-2 Illustrations .............................................................................................................................................................................. i-7 Symbols ..................................................................................................................................................................................... i-3 To The Owner and Operator ................................................................................................................................................. i-2 Introduction B and C Series Page i-1

To The Owner and Operator Page i-2 Section i - Introduction B and C Series To The Owner and Operator Preventative maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedule recommendations outlined in Maintenance Guidelines (Section 2). Keep records of regularly scheduled maintenance. | Use the correct fuel, oil and coolant in your engine as specified in Specifications and Torque Values (Section V). Cummins Engine Company, Inc. uses the latest technology and the highest quality components to produce its engines. Cummins recommends using only genuine Cummins parts and ReCon exchange parts. Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts support. If you have a problem that cannot be resolved by a Cummins Authorized Repair Location, follow the steps outlined in the Service Assistance (Section S). Review the Owners Responsibilities in (Section W). NOTE: Discharge of oil or oily waste into or upon the water is a direct violation of todays laws. Violators are subject to a penalty of various monetary charges. Dispose of these substances properly. About the Manual This manual contains information needed to correctly operate and maintain your engine as recommended by Cummins Engine Company, Inc. Additional service literature (Shop Manual, Troubleshooting and Repair Manual) can be ordered by filling out and mailing the Literature Order Form located in Service Literature, (Section L). This manual does not cover vessel or equipment maintenance procedures. Consult the vessel or equipment manufacturer for specific maintenance recommendations. Both metric and U.S. Customary values are listed in this manual. The metric value is listed first, followed by the U.S. Customary in brackets. Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to page i-3 through i-6 for a complete listing of symbols and their definitions. Each section is preceded by a “ Section Contents” to aid in locating information more quickly. How to Use the Manual This manual is organized according to intervals at which maintenance on your engine is to be performed. A table which states the required intervals and the checks to be made is located in (Section 2). Locate the interval at which you are performing maintenance, then follow the steps given in that section for all the procedures to be performed. In addition, all the procedures done under previous maintenance intervals must be performed also. Keep a record of all the checks and inspections made. A record form for recording date or hours, and which maintenance checks were performed is located in (Section 2). Refer to (Section T) for a guide to troubleshooting your engine. Follow the directions given on page T-2 to locate and correct engine problems. Refer to (Section V) for specifications recommended by Cummins Engine Company, Inc., for your engine. Speci- fications and torque values for each engine system are given in that section.

Introduction B and C Series Symbols Page i-3 Symbols The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below: ▲ A -j WARNING - Serious personal injury or extensive property damage can result if the warning instructions are not followed. CAUTION - Minor personal injury can result or a part, an assembly, or the engine can be damaged if the caution instructions are not followed. $ Indicates a REMOVAL or DISASSEMBLY step Indicates an INSTALLATION or ASSEMBLY step INSPECTION is required. CLEAN the part or assembly. PERFORM a mechanical or time MEASUREMENT ^ | LUBRICATE the part or assembly. Indicates that a WRENCH or TOOL SIZE will be given. TIGHTEN to a specific torque. PERFORM an electrical MEASUREMENT <s> Refer to another location in this manual or another publication for additional information. The component weighs 23 Kg [50 IbJ or more. To avoid personal injury, use a hoist or get assistance to lift the component.

Cummins operation and Maintenance B & C marine propulsion.

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